CUTTING TOOLS
[2.2 m/min] and hold blade to blade profiles 0.001" [0.03-mm] tolerance over the blade surfaces, blade to blade, and leading edge to trailing edge. They are pushing 120 ipm [3.0 m/min] and would like to get to 160–180 ipm [4–4.5 m/min]. Cutting tools are getting better, but titanium is tough on end mills and aerospace-type parts. Today, we’re getting 60–90 minutes per cutting edge which is pretty much standard in cutting 6 Al- 4V. Ten years ago it was 10 minutes,” Walker said. “Newer developments affect literally every aspect of the machining process,” said Walker. “They include determining the right spindle connection [Kennametal’s KM4X], adopting the latest cutting toolpath strategy [trochoidal and constant chip volume approaches], and CNC controls with tool point center control with smoothing algorithms [Siemens 840 D and Fanuc i31 CNC].”
Testing Leads to Robust Titanium Machine Design According to Mark Larson, manager of process R&D, Makino Inc. (Mason, OH) testing inserted tools for roughing,
measuring cutting forces on the machine and tool wear, look- ing for ways to improve lubricity through coolants, and using the latest toolpaths for milling are essential to optimize the titanium machining process. The Titanium Process Develop- ment group at Makino, has focused on testing machines de- signed specifically to address titanium machining challenges including high hardness, high strength, heat resistance, and harmonic issues.“On our T series machines we can maintain 787 ft-lb [1067 N•m] of torque all the way up to 980 rpm. That’s a lot different from previous machines. Most of them especially the gear driven spindles start to fall off around 230 rpm, depending on the size of the cutter and how fast you’re running and what your tool life is. That 230 rpm might be okay in some cases, but if you want to be more productive you want to be able to run at a higher speed and remove metal faster. We like having that high torque at higher rpm,” said Larson.
The Original The only true solution for roughing
and trochoidal milling operations in the industry.
“Our T series machines routinely use 1000 psi [6.89 MPa] with 52 gpm [196 L/min] through the spindle. Let’s say we have a 3" [76-mm] roughing tool with as many as 30 inserts on that tool. We want coolant going to each insert. There are a lot of orifices to feed cool- ant through and we want to make sure we have enough flow so we don’t lose pressure for each of the inserts. We want a very good flow rate and high pressure to prevent chips from being recut by efficiently moving them out of the way,” said Larson.
“There has been a
decided shift to materials- centered manufacturing.”
“We see many more customers in- Tooling Technology Shrinking Technology Balancing Technology
Haimer USA, LLC | 134 E. Hill Street | Villa Park, IL 60181 | Phone: +1-630-833-1500 Email:
haimer@haimer-usa.com |
www.haimer-usa.com
Measuring Instruments
terested in five-axis machining because even if they don’t need five-axis simul- taneous motion, it reduces the number of setups and allows them to keep the part fixtured once, for more accuracy. There’s a definite trend for shrink-fit holders to use anti pullout types of adapters like the Haimer Safe-Lock to prevent solid tools from being pulled
50
AdvancedManufacturing.org | January 2016
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